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600 - 10,000 scfm | AES Series

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AES Series Energy SavingRefrigerated Air Dryer

600 - 10,000 scfm

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Based on AES-2000; Cost of power: $0.10 kWh; 8,760 operating hours

AES Series Energy SavingRefrigerated Air Dryer600 - 10,000 scfm

Since 1994, Aircel has been

delivering quality, industry

leading compressed air dryers

and accessories for production

lines and facilities all over the

world.

Our precise engineering

and designs provide reliable

products that will protect your

operations for years to come.

Based in Maryville, Tennessee,

Aircel is a multi-industry

manufacturing leader. Aircel’s

highly-specialized, engineered

products and technologies

are powering facilities all over

the world. Our products serve

industries such as textile, food

and beverage, automotive,

production, PET market,

breathing air, pneumatic

instrumentation, and more.

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Air Load %

Ener

gy C

onsu

mpt

ion

%

Key

AES Series

Non-Cycling

Due to the increasing cost of energy around the world, the compressed air industry has been challenged to create a dryer to deliver long-term energy savings.

To address this need, Aircel engineers designed the AES Series - a dryer that precisely matches power usage to inlet air demand.

AES dryers automatically modulate the refrigeration compressor on and off, delivering significant power and energy savings to your bottom line.

Significant Savings

Load % Energy Consumption % Power (kW) Energy Savings

(kW) Yearly Savings

100% 100% 13.10 -- --

75% 79% 10.21 2.88 $ 2,524

50% 55% 7.20 5.89 $ 5,162

25% 34% 4.32 8.77 $ 7,686

0% 10% 1.31 11.79 $ 10,325

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600 - 10,000 scfm | AES Series

What Makes the AES Series Different?

Designed for Superior Performance · The compact, stainless steel heat exchangers pre-cool the air with the outgoing cold air to minimize energy consumption while maintaining the required dew point.

• Chevron design creates turbulent flow, allowing the air to flow freely and efficiently.

• Delivers ISO 8573-1:2010 Air Quality Class 4 pressure dew point.

• Heat exchangers and air lines are wrapped in non-degrading insulation to maintain highest thermal efficiencies.

Engineered for Savings· AES Series digital scroll compressors modulate on and off immediately and accurately based on system demand. This uses less energy when demand is lower, delivering proportional energy savings.

• Digital compressor is the most efficient compressor over widest range of inlet flow conditions.

• Highly reliable, proven design.

• 71% fewer parts provide greater reliability and significantly decreased maintenance than reciprocating compressors.

• Dryers utilize R-404a refrigerant.

Created for System Protection· Aircel’s zero loss condensate drain provide effective condensate removal without the loss of compressed air.

• Push to test button ensures system operation reliability.

Constructed for Ease· Each cabinet is designed for easy service accessibility. Each cabinet provides easy access to critical components located inside.

• Dryer enclosure opens, providing access for routine maintenance.

• Powder coated cabinets look great for years to come, while protecting the inner workings of the dryer from harsh environments.

• Inlet and outlet air connections located at the top provide installation ease.

AircelEnergySavings

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AES Series | 600 - 10,000 scfm

Easy-to-Read Pressure Gauges2.5” air inlet pressure, air inlet temperature, suction pressure, and discharge pressure let you immediately see what is happening in the dryer

Air-to-Air Heat ExchangerUtilizes outgoing air to cool the incoming air, providing additional energy savings

High Efficiency SeparatorRemoves 99% of bulk water while increasing dryer reliability

4” LCD Touch ScreenEthernet connection ready screen displays energy savings feedback, hours saved, instantaneous load, alarms, status, and more

Air-to-Refrigerant Heat ExchangerEach plate creates turbulent flow, providing a self-cleaning effect that provides corrosion resistance and increases longevity

Digital Scroll CompressorLoads and unloads immediately to match inlet air system demand from 10% to 100%

Zero Loss Condensate DrainPneumatically operated demand drains waste no compressed air

AES Features

As your plant conditions grow and change, the AES Series is able to expand with you. Increase drying power with modular units, configured in 500 and 1,000 scfm increments to precisely match your air flow demand from 10% to 100%.

Interface up to five modular dryers with isolation valves to expand drying capability. These modular systems provide back-up drying and lower pressure drop without increasing power consumption.

The System That Expands With You

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600 - 10,000 scfm | AES Series

More Control at Your Fingertips

Standard Control Features

• NEMA 4 steel electrical enclosure

• Ethernet-ready connectivity to connect to plant control system

• Allen-Bradley MicroLogix 1100E PLC controller

• 4” LCD color touch screen

• On-screen display of dryer operation status

• 10/100 mb/s with built-in peer-to-peer messaging

• Communication through RS-232/RS-486 combo port

• UL, CE, C-Tick, and Class 1 Div. 2 certified controller

• Supports DHCP

• Add up to four 1762 I/O modules

• Phase monitoring protects compressor while eliminating possible phase reversal, loss, and unbalance

• Energy savings based upon demand

Standard Control Alarms

• High discharge line temperature alarm

• Locked rotor alarm

• Three-phase refrigeration compressor open circuit alarm protects compressor while eliminating possible phase reversal, loss, and unbalance

• Maximum continuous current alarm

• Discharge line thermistor open sensor alarm, thermistor short alarm, and transducer failure alarm

• Suction line transducer failure

• Condenser transducer failure

• Refrigeration copressor low temperature alarm

• Refrigeration compessor high temperature alarm

• Condenser fan motor low temperature alarm

• Condenser fan motor high temperature alarm

Standard Control Readout

• Refrigerant suction line pressure

• Refrigerant suction line temperature (°F)

• Refrigerant discharge line pressure

• Refrigerant discharge line temperature (°F)

• Fan(s) on/off status

• Unloader solenoid on/off status

• Alarm warning

AES Series dryers come standard with industry leading controller technology providing the easiest, most innovative way of monitoring dryer status.

Each AES Series dryer includes a user-friendly 4” LED touch screen with ethernet-ready capabilities to connect to your existing system. This screen control monitors system performance, operation of the digital scroll compressor, and tracks energy savings, while displaying system operational steps.

• Energy saving control for more efficient operation.

• Easy-to-read display provides continuous operating feedback.

• Event log stores critical data.

• Ethernet capability for web-based remote monitoring.

• Multiple alarms and safeties protect your investment.

• Main control menu

• Alarm status screen

• Immediate pop-up alarm banner

• History log with alarm date and time stamp

• Service option information

• Touch system control

• Days of operation, hours of energy savings, system timers, and mode of operation

On-Screen Features

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AES Series | 600 - 10,000 scfm

DrainValve

Air or WaterCooled

Condenser

AirCompressor

DrainValve

Dry Airto Plant

DrainValve

VF Series

After Filter

Pre-Filter

Wet Receiver(optional)

Dry Receiver(optional)

Separator

DrainValve

Recommended Installation

How It Works

• Saturated, compressed air enters the system and moves into the pre-cooler/re-heater (A), where it is pre-cooled by the cold outgoing air.

• The air is then directed through the air to refrigerant heat exchanger (B), where it is cooled to 38°F by the refrigeration system.

• The cold, saturated air flows into the three-stage separator (C), where liquids are removed from the air and ejected from the system via the Aircel condensate drain (D).

• The cold, dry air is then reheated by the incoming warm air (E) before leaving the dryer.

A B

D

E

Condenser

DigitalCom

pressor

Expansion Valve

Separator

Pre-Cooler/Re-heater Air to Refrigerant

Drain

RefrigerantOut

Air In

Air Out

C

Digital Scroll

Advanced digital scroll technology, utilized in AES Series dryers, maintains a constant dew point while saving

up to 91% energy savings while in operation. This savings is achieved through a communication with the

system evaporator via temperature probe, adjusting refrigeration capacity to the temperature of the air

exiting the evaporator. This technology saves the highest amount of energy possible in a refrigerated air

dryer.

Non-Cycling

Non-cycling dryers utilize a hot gas bypass to maintain a constant dew point and conrol the amount of

refrigerant flowing through the dryer. Energy consumption stays the same, no matter the flow and air

demand. Dryers utilizing a hot gass bypass are ideal for situations running mainly at full load.

Thermal Mass Storage

Cycling systems typically rely on a thermal mass comprised of propylene glycol to store cool energy, allowing

the compressor to be cycled on and off. Energy savings are realized when the compressor is turned off.

Refrigerated Dryer Styles Explained

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600 - 10,000 scfm | AES Series

Capacity rated in accordance with CAGI ADF 100 @ 100 psig, 100°F inlet, 100°F ambient and a PDP of 38°FOperating pressure: 40 to 232 psig | Ambient air temperature: 40°F to 120°F (35°F with low ambient option) | Inlet air temperature: 40°F to 120°FFor larger capacities and custom dryer options, please contact an Aircel factory representative

Capacity Correction Factors

Ambient Temperature (°F) 70 80 90 100 110 115 120

Correction Factor 1.1 1.07 1.05 1 0.94 0.85 0.65

Correction Factors for Differing Ambient Temperature (C1)

Inlet Temperature (°F) 80 90 100 110 120

Correction Factor 1.5 1.21 1 0.82 0.75

Correction Factors for Differing Inlet Air Temperature (C3)

System Pressure (psig) 50 75 100 125 150 175 200 225

Correction Factor 0.85 0.95 1 1.07 1.13 1.18 1.2 1.22

Correction Factors for Differing System Air Pressure (C4)

Dew Point (°F) 38 41 45 50

Correction Factor 1 1.12 1.17 1.22

Correction Factors for Differing Pressure Dew Point Requirements (C2)

To Size the Dryer Capacity for Actual ConditionsAdjusted Capacity = scfm x (C1 x C2 x C3 x C4)Example: Dryer Model: AES-800 Standard Capacity: 800 scfm Actual Operating Conditions: 90°F ambient: C1 = 1.05 50°F required dew point: C2 = 1.22 110°F inlet: C3 = 0.82 100 psig system pressure: C4 = 1

Adjusted Capacity: 800 scfm x 1.05 x 1.22 x 0.82 x 1 = 840.3 scfm

To Size the Dryer Model for Actual ConditionsAdjusted Capacity = scfm / (C1 / C2 / C3 / C4)Example: Given Flow: 2,000 scfm Actual Operating Conditions: 80°F ambient: C1 = 1.07 38°F required dew point: C2 = 1 100°F inlet: C3 = 1 200 psig system pressure: C4 = 1.2

Adjusted Capacity: 2,000 scfm / 1.07 / 1 / 1 / 1.2 = 1,557.6 scfmSelected Dryer Model: AES-1,750

Dimensions (in.)

ModelNumber Capacity Voltage

Connection (FLG) Weight (lbs) Height Width Depth Refrigerant

Air-Cooled kW (full load)

Max. Pressure

Nominal Ref HP Installed

[(quantity) size] Optional Voltage Ratings

AES-600 600

460-3-60

3” NPT 645 45 34 45

R-404a

5.48

232

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208/230-3-60; 460-3-60; 575/600-3-60

AES-800 800 3” NPT 805 48 38 54 6.55 4

AES-1000 1,000 3” NPT 810 48 38 54 7.81 5

AES-1250 1,250 3” NPT 860 48 38 54 9.49 6

AES-1500 1,500 4” 1,650 84 58 41 11.49 7.5

AES-1750 1,750 4” 2,250 84 58 41 14.88 10

AES-2000 2,000 4” 2,300 84 58 41 17.53 10

AES-2500 2,500 6” 2,370 52 114 65 18.98 (2) 6

AES-3000 3,000 6” 3,980 110 124 44 22.98 (2) 7.5

AES-3500 3,500 6” 5,180 110 124 44 29.75 (2) 10

AES-4000 4,000 6” 5,258 110 124 44 35.06 (2) 10

AES-4500 4,500 8” 6,408 102 186 44 36.46 (3) 7.5

AES-5250 5,000 8” 8,208 102 186 44 46.63 (3) 10

AES-6000 6,000 8” 8,358 102 186 44 54.58 (3) 10

AES-7000 7,000 10” 11,623 109 247 44 59.50 (4) 7.5

AES-8000 8,000 10” 11,823 109 247 44 70.11 (4) 10

AES-8750 9,000 12” 15,528 111 308 47 74.38 (5) 7.5

AES-10000 10,000 12” 15,778 111 308 47 87.64 (5) 10

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AES Series | 600 - 10,000 scfm

323 Crisp Circle · Maryville, TN 37801 | office: 865-681-7066 | sales@airceldryers.com

Please visit us at airceldryers.com

Aircel, LLC. reserves the right to update or change specifications at any time without prior notice.

MADE INTHE USA